AU2005287880A1

AU2005287880A1 - A block wall system

Info

Publication number: AU2005287880A1
Application number: AU2005287880A
Authority: AU
Inventors: Oliver Kohl; Craig Stephen Thorley
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-09-23
Filing date: 2005-09-22
Publication date: 2006-03-30
Anticipated expiration: 2025-09-22
Also published as: WO2006032100A1; AU2005287880B2; NZ554067A

Description

WO 2006/032100 PCT/AU2005/001455 1 TITLE "A BLOCK WALL SYSTEM" FIELD OF THE INVENTION This invention relates to a block wall system. In particular, the 5 invention relates to a block wall system that utilises expansion joints. BACKGROUND OF THE INVENTION Blocks or bricks are commonly used in the building of walls. Block walls of large- spans are- prone -to- cracking--due to the expansion and contraction of the blocks with the walls. In extreme circumstances, a block 10 wall may completely fail due to the forces created with continued expansion and contraction of the blocks. In order to combat block walls failing, it has been necessary to provide a space, known as an expansion joint, between various sections of blocks walls to allow for expansion and contraction of the blocks. Expansion 15 joints bridges have been developed so that various sections of the block wall are physically joined so that the sections form a single wall yet expansion and contraction of the blocks will not cause failure of the wall. A very popular expansion joint bridge includes a dowel and a sleeve. The dowel is able to reciprocate within the sleeve. The dowel is 20 secured to a first block in a first section of the block wall and the sleeve is secured to a second block in a second section of the block wall. When the wall expands or contracts, the dowel moves back and forward within the sleeve. This allows the separate sections of the block wall to act as a single block wall yet provides protection against cracking due to expansion and 25 contraction, In any expansion joint gap between two sections of walls there are normally expansion joint bridges or dowels placed across the expansion joint gap at every second course of blocks. It is essential that these dowels located within a single gap are parallel to each other and parallel to the 30 longitudinal line of the wall to allow expansion and contraction of the block wall. If the dowels are not parallel to each other, then dowel and sleeve will prevent movement. Over time, this is likely to cause cracking and possible WO 2006/032100 PCT/AU2005/001455 2 failure of the block wall. To align the dowels and sleeves when building a block wall is difficult and time consuming. Further, even when perfect alignment is achieved, the alignment may be disturbed when a core of the block is filled 5 with concrete. OBJECT OF THE INVENTION It is an object of the invention to overcome or alleviate one or more-of the above disadvantages-or provide-the- consumer with a useful or commercial choice. 10 SUMMARY OF THE INVENTION In one form, although not necessarily the only or broadest form, the invention resides in a block wall system comprising: a first block and a second block, the first block and the second block separated by a gap; 15 a saddle located within each of the blocks, the saddle including a seat to seat a dowel in a predetermined position; and a dowel that sits within the seat of each saddle of each block. In another form, the invention resides in a method of constructing a block wall system including the step of: 20 locating a dowel within a first seat of a first saddle located within the first block; and locating the dowel within a second seat of second saddle located within a second block. The method may also include the step of locating a saddle 25 within a block. In another form, the invention resides in a block for use in a block wall system comprising: at least a pair of side walls and at least a pair of end walls; and at least one saddle extending between the at least pair of side 30 walls; wherein the saddle has a seat to seat a dowel in a predetermined position.

WO 2006/032100 PCT/AU2005/001455 3 In another form the invention resides in a saddle for use in a block wall system, the saddle comprising: a seat to seat a dowel in a predetermined position; a depth positioner to position the seat at a predetermined depth 5 relative to a block, and a lateral positioner to position the seat in a predetermined orientation with respect to a block. DETAILED DESCRIPTION-OF-THE DRAWINGS Embodiments of the invention, byway of examples only, will be 10 described with reference to the accompanying drawings in which: FIG. 1 is a perspective view of a saddle according to a first embodiment of the invention; FIG. 2 is a perspective view of block wall system using the saddle of FIG. 1; 15 FIG. 3 is a further perspective view of a block wall system using the saddle of FIG. 1; FIG 4A is a perspective view of a block for use in a block wall system according to a first embodiment of the invention; FIG 4B is a perspective view of a block for use in a block wall 20 system according to a first embodiment of the invention; FIG. 4C is a side sectional view of the block of FIG. 4A; and FIG. 4D is a side sectional view of the block of FIG. 4B. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. 1 shows a perspective view of a saddle 10 for use in an 25 expansion joint. The saddle 10 is constructed from a single sheet of mild steel. However, it should be appreciated that the saddle 10 may be formed from any suitable materials such as plastic. The saddle 10 includes a seat 30, a depth positioner 40 and a lateral positioner 50. The seat 30 in the form of a web 31 has a semi-circular 30 hole 32 located within the web. A depth positioner 40 is formed by two tongues 41 that extend outwardly from the sides of the web 31. The lateral positioner 50 is in the form of two flanges 51 that extend sideward from the WO 2006/032100 PCT/AU2005/001455 4 web. The two flanges 51 are perpendicular to the web 31 and the two tongues 41. It should be appreciated that in another embodiment the two flanges may be resilient and may be formed at an obtuse angle with respect to the web. The two flanges may therefore be bent with respect to the web in 5 order to insert the saddle. FIG. 2 shows a block wall system 60 that utilises two saddles. A saddle 10 is positioned within each of the two blocks 61 by simply pushing the saddle 10. into the block- 60. The two flanges 51 of the saddle 10 are spaced apart by the web 31 so that they fit tightly against the inside faces of 10 the respective blocks 61. As the flanges 51 are parallel to each other and abut against the blocks 61, the flanges 51 cause the seat 30 to be in a parallel orientation with respect to the opposing seat 30. The two tongues 41, which form the depth positioner 40, enable the saddle 10 to be pushed downwardly until the two tongues 41 15 engage the top of the block 61. When the two tongues 41 touch the top of the block 61, this positions the seat 30 at a predetermined depth. The two tongues 41 that extend outwardly from the web 31 are of a height that is less than the height of cement that separates and joins the blocks together. Once the saddles 10 are positioned within respective blocks 20 61, a metal dowel 70 is ready to be placed within the semi-circular hole 32 of each of the two saddles 10. A grease cap 71 and grease 72 are located on one side of the dowel 70 prior to location of the dowel 70 within the semi circular hole 32. Once the dowel 70 is placed within the semi-circular hole 32 and the block wall has been completed, concrete (not shown) is poured 25 through the blocks in a normal manner. The grease 72 prevents the concrete from curing against the dowel 70 and hence the dowel is able to move with respect to the block 61. It should be appreciated that grease may be replaced with other coatings such as bitumen or tar. The side of the dowel 70 that does not have grease located on the dowel is held firmly by the 30 cured concrete. In this manner the dowel allows contraction and expansion of the blocks without causing cracking. The saddle 10 enables each of the dowels 70 in an expansion WO 2006/032100 PCT/AU2005/001455 5 joint to be placed in a parallel alignment quickly and effectively, as shown in FIG. 3, thereby protecting the wall from failing. That is, the dowels 70 are located parallel to each other by using the saddle without the need for great care. Further, the saddle 10 does not change how block walls are currently 5 constructed. FIGS. 4A and 4C show a block 80 that has two saddles 90 that are integrally moulded into the block. The block is used to produce a block wall-system in-the manner described above. The block 80 has two side walls 81 and two end walls 82. The 10 saddle 90 extends between the two side walls 81. A seat 91 is located within the middle of each saddle 90 at a predetermined position that is of a desired depth and a desired lateral distance from the side wall. FIGS. 4B and 4D show a further embodiment of a block containing a saddle. The seat is of a different configuration. However, the 15 block 80 functions the same as the block described in FIG 4A. It should be appreciated that various other changes and modifications may be made to the embodiments described without departing from the spirit or scope of the invention.

Claims

1. A block wall system comprising: a first block and a second block, the first block and the second block separated by a gap; 5 a saddle located within each of the blocks, the saddle including a seat to seat a dowel in a predetermined position; and a dowel that sits within the seat of each saddle of each block. 2 The block wall system of ,claim 1 wherein the saddle is integrally formed with the first block and the second block. 10 3. The block wall system of claim 1 wherein the saddle is formed separately to the first block and the second block.

4. The block wall system of claim 3 wherein the saddle comprises: a depth positioner to position the seat at a predetermined depth relative to a block; and 15 a lateral positioner to position the seat in a predetermined orientation with respect to a block.

5. The block wall system of claim 4 wherein the seat has a hole located within a web.

6. The block wall system of claim 5 wherein the depth positioner 20 is formed by two tongues that extend outward from the web.

7. The block wall system of claim 5 wherein the lateral positioner is formed from two flanges that extend sideward from the web.

8. The block wall system of claim 1 wherein the dowel is made of metal. 25 9. The block wall system of claim I wherein a grease cap is located over at least one end of the dowel.

10. The block wall system of claim 1 wherein a coating is located on the dowel.

11. A saddle for use in a block wall system, the saddle comprising: 30 a seat to seat a dowel in a predetermined position; a depth positioner to position the seat at a predetermined depth relative to a block; and WO 2006/032100 PCT/AU2005/001455 7 a lateral positioner to position the seat in a predetermined orientation with respect to a block.

12. The block wall system of claim 3 wherein the saddle comprises a depth positioner to position the seat at a predetermined depth 5 relative to a block; and a lateral positioner to position the seat in a predetermined orientation with respect to a block. 1-& - The block wall-system of claim 4 wherein the seat has a hole located within a web. 10 14. The block wall system of claim 5 wherein the depth positioner is formed by two tongues that extend outwardly from the web.

15. The block wall system of claim 5 wherein the lateral positioner is formed from two flanges that extend sideward from the web.

16. A block for use in a block wall system comprising: 15 at least a pair of side walls and at least a pair of end walls; and at least one saddle extending between the at least pair of side walls; wherein the saddle has a seat to seat a dowel in a predetermined position. 20 17. The block of claim 8 wherein the saddle is integrally formed within the block.

18. A method of constructing a block wall system including the steps of: locating a dowel within a first seat of a first saddle located 25 within first block; and locating the dowel within a second seat of second saddle located within a second block.

19. The method of claim 1 further including the steps of placing the first saddle within the first block and placing the second saddle within the 30 second block.

20. The method of claim 1 further including the step of applying a coating to the dowel. WO 2006/032100 PCT/AU2005/001455 8

21. A block wall system comprising: a first set of blocks and a second set of blocks, the first set of blocks being separated by a gap from a second set of blocks; at least two saddles located within at least two blocks of the 5 first set of blocks; at least two saddles located within at least two blocks of the second set of blocks each of the saddles including a seat to seat a dowel in a predetermined position; and 10 at least two dowels that extend between the first set of blocks and the second set of blocks and are located within the seats of the respective saddles of the blocks; wherein the dowels are parallel to each other.